Lead QA/QC Engineer
ENOC
مجموع سنوات الخبرة :33 years, 0 أشهر
Provides Quality Management during detailed design, procurement, construction and installation.
• Managing Third Party Consultancy Agreement/Contract for Worldwide Inspection, Site Inspection and Project Quality Assurance & Compliance Audits.
• Assigning and Co-ordination for Inspection & Audits, Issuance of service Orders and approval of Invoices (TPIA)
• Review and Tracking of TPI Inspection Reports, Inspection Release Notes and Audit Reports.
• Prepare Surveillance and Audit Plans and ensure their successful implementation across the Project.
• Provide direction, guidance and quality resources to support the Project Management Team.
• Review of Contractors Quality documents, Project Quality Plan, Inspection Test Plans, Welding & NDT Procedures, Painting Procedures, Hydrostatic procedures & Method Statements.
• Lead & Participate in Project Quality & Compliance Audits.
• Review of CVs, conduct interviews & approval of Quality personnel of TPI & contractors.
• Conduct Quality Walk Through, Surveillance and oversight of contractors’ implementation of their Quality Programme and compliance with Project Requirements.
• Established, Implemented and maintained Business Continuity Management System in EPCL as per ISO 22301:2012
• Defined Context of Organization, Internal and External Parties with interlinking of interested Parties, Needs & Expectations and Risks & Opportunities.
• Active Participation and lead in Review and preparation of Business Impact Analysis (BIA), Business Continuity Plans(BCPs), Business Continuity Strategy and BCMS Manual.
• Active participation and lead in review and preparation of Audit Plans, Exercise & Testing plans, Business Continuity Objectives, KPIs and Awareness Plans.
• Active participation and lead in BCMS Internal Audits, Management Review Meeting and Exercise & Testing
• Active participation in Risk Assessment of Business Continuity related risks.
• Communication of Business Continuity Awareness throughout the organization through Power Point Presentations.
• Integration of company ICS system with BCMS
• Tracking and Close out action plan of external audit findings.
• Facilitating Business Continuity Capability evaluation of key vendors.
• Performance measurement and continual improvement of BCMS
• Select Accomplishments & Challenges:
• Achieved BCMS Certification for the company as per ISO 22301:2012 in 3 months.
• Established BCMS and prepared all the related documents including BCMS Manual.
• Conducted and participated in Internal audit, Exercise & Testing and Management Review Meeting
• Timely closure of External Audit Findings with suitable corrective actions and Root Cause Analysis.
• Optimization of Third Party Inspection Contract.
• Manage the oversight of contractors and Quality related activities and deliverables.
• Inspection, Co-ordination and expediting of Pressure Vessels and Skids.
• Interface with Cameron Schlumberger, Client representatives (Eni & TPI) and Manufacturer Specialist representatives.
• Monitor and report quality issues and performance of Manufacturer to Cameron-SLB
• Review of Quality Dossiers and Manufacturer Record Book (MRB)
Ensures the PMT/PMC and contractors apply the Quality Assurance / Quality Control strategy in a structured and consistent manner. Develops the Quality Management System within division that shall cover both the project execution processes as well as the verification of the delivered product.
• Ensures quality requirements are captured in the ITT documents, PEP and PQP and assure that the Project scope is conducted in accordance with approved and adequate Quality and Integrity Management Systems, specifications and codes and standards.
• Supports investigations in relation to project activity failures or quality issues. Ensures Quality risks related are identified and that mitigation plans are established and managed.
• Participate in incident failure investigations including cause tree analysis, SWOT analysis, Recommendations and preparation of the Report.
• Review and Approval of Quality Control Plans/Inspection Test Plans, WPS, PQR, WPQ, NDT Procedures and NDT Technicians of all suppliers and sub-contractors.
• Review and approval of Painting procedures and quality related procedures including Hydrostatic test, Pneumatic Test, Procurement, document control etc.
• Review and evaluate the quality assurance aspects of the tender documents submitted by EPC/TPA contractors against ADMA-OPCO approved scope of work, standards and quality assurance criteria.
• Evaluates audit findings, reports and follow up on implementation of audit findings and Recommended corrective actions.
• Participates in Pre-qualification audits of contractors / vendors / consultants to verify compliance with quality assurance requirements and guidelines.
• Ensures, as built documentation of the Contractor and Manufacturer's Record Books (MRBs) of the Vendors / Sub-contractor are as per the project requirements.
• Takes accountability and responsibility for all technical decisions and deliverables related to QA/QC aspects for all stages of ADMA-OPCO's Projects. Provides technical advice to the Project Teams of ADMA-OPCO on all matters related to Quality Management Systems and procedures.
• Plans and conduct awareness sessions, campaigns and training on Project Quality Assurance to enhance project quality culture.
• Follows the company health, safety and environmental policy, procedures, regulations and objectives related to the area of responsibility. Ensures that work is performed in a safe and environmentally sound manner.
• Performs other related duties as assigned by Manager/Team Leader such as participating in the training and development of UAE National employees assigned, including assessing employee's training and development needs.
• Performing Project Quality Audits of PMT/PMC within ADMA and Contractors
• Based on audits, reviews and observations identify gaps and possible risks from quality perspective that may impact project quality and schedule.
• Share knowledge and lessons learnt, bench marking within the ADMA project teams and from worldwide oil and gas projects and benefit to ADMA projects.
• Review and approval of Contractors/Suppliers’ quality personnel.
• Lead & Participate in QMS Internal Audits to verify compliance with ISO 9001:2008 and functional procedures.
Select Accomplishments & Challenges:
• Certificate of recognition in valuable contribution and participation towards the success of “Quality Risks in Projects” workshop
• Certificate of recognition in valuable contribution and participation towards the success of “TPA Management in Projects” workshop
• Certificate of recognition in valuable contribution and participation towards delivering a successful Umm Shaif Cross Asset Technical Audit
• Managing a large portfolio of more than 50 projects and with new strategies
• Participation in revision of ADMA Quality standards and specifications
• Participation of various incident investigations, which involved detailed Cause Tree Analysis, SWOT Analysis, Recommendations and preparation of Reports.
Develop quality management framework and implement verification processes for the design, procurement, fabrication, construction, and commissioning and operations phases
Participate and coordinate the evolving management processes like DCAF, FPD, and CCMS
Facilitate during finalizing project deliverables at concept, FEED, detail design, construction and commissioning phases in line with PDO code of practice, specification and procedures
Conduct quality awareness training
Participate in the development of PEPs, PQPs, in line with PDO policies and procedures
Carry out gap analysis of Quality Management as and when required
Conduct external audits on project design contractors, suppliers, Contractors, and vendors
Supervise the cluster construction quality and inspection personnel of project
Identify quality goals, audit plans and maintain audit records, NCR, Corrective action and close out records
Based on the audit reviews and observations identify gaps and possible risks from quality perspective that may impact project quality and schedule
Review material specifications supplier records and technical reports in terms of quality aspects
Review and approval of contractors/suppliers PQP, ITP and CQP
Review and approval of Contractors/ suppliers/ TPI Quality personnel
Participate in Vendor Assessment, Pre-Inspection meetings, Equipment/Material inspection, FAT processes
Liaise with project/Site Quality team to review the vendor documentation packs/Manufacturing Record Book for its technical compliance and accurate.
Conducting/ coordinating vendor assessment audits with the discipline engineers as required
Participate/ lead Quality Management review meeting the contractors.
Participate in the kick off and Pre-inspection meetings and advice on all the quality related requirements
Inspection and surveillance of various material and equipment and review of Test certificates & Test Reports as per Shell Specifications (MESC, SPE & DEP) and PDO Specifications SP & ERD’s & international standards. The material includes various flow lines, On plot piping material (Carbon steel, Stainless steel, Duplex stainless steel), Fabricated fittings, GRE pipes, Valves like Ball valves, Gate valves, Globe valves, Check valves, safety relief valves, Control Valves, ESD Valves, Centrifugal pumps, Cavity Pumps, PE liners, Pressure Vessels, Silos, Tanks, Flare System, Nitrogen Generation Package and Air Compression Package etc.
Managing Third party inspections and certification for the material and equipment at manufacturer’s location
Inspection of incoming material & review of material test certificates as when required.
GRE: Review and approval of Inspection test plans, 1000-hour Qualification Procedures, test spools and calculations, qualification of Supervisors/Quality inspectors & bonders, Quality control procedures, Method statements and repair procedures.
Challenges & Select Accomplishments:
Managing a large portfolio of around 40 projects & various small projects
Coordinating with corporate Quality function, contractor’s quality team & Projects Team
Making awareness of Quality Management System requirements and lessons learnt to the vendors, Suppliers, Main contractor & Sub contractors
Focal point and accountable for all the QA/QC issues, activities and resolutions
Non-standard piping class for polymer and thiourea transfer lines
On Plot GRE above ground piping ranging from 2” to 24” and design pressures from 10 bar to 30 bar
Producing high quality work output in a timely manner to meet the company’s intensive project activity schedules
Awarded Shukrans in recognition for the effort and support provided beyond expectation in successfully completing the technical review of GRE design, Pre qualification, manufacturing and installation while all agencies were going through learning curve in applying GRE for the above ground & successfully completing the project.
Inspection of various Static, rotating equipment, Oil & Gas cross country pipelines, Drill pipes, Casing pipes & Tubing, drill bits, various types of hoses for Oil & Gas companies, Refrigerant cylinders & LPG cylinders for export.
Technical Proficiency and Inspection in OCTG Tubulars (Drill Pipes, Casing and Tubing), Premium Connections, Material Knowledge, Welding, NDT, Testing and OCTG Standards.
Plan, Lead, conduct & participate in external audits to verify implementation and compliance with company’s standards, specifications, client requirements and ISO 9001-2000 on Vendors & Manufacturers, Main contractors & Sub contractors
Plan, Lead, conduct & participate in internal audits as per the company standards and ISO 9001-2000
Surveillance audits of pipe line projects of Gas Authority of India limited on Jam Nagar-Loni LPG pipeline project and Dahej-Vijaypur LNG Projects and Booster station at Samakhiyali-GAIL
Inspection of various Static, rotating equipment, Oil & Gas cross country pipelines, Drill pipes, Casing pipes & Tubing, drill bits, various types of hoses for Oil & Gas companies, Refrigerant cylinders & LPG cylinders for export.
Inspection of various electrical equipment and items like Panels, Transformers, Circuit Breakers, Isolators, Motors, Battery and Battery Chargers, Cables and lightening Arrestors
Business development & achieving budgeted figures set by the management
Conducted technical discussions and advice on all quality related requirements to clients.
Preparation and approval of technical quotations submitted for business purposes.
Responsible as State coordinator for surveillance audits of IOCL & HPCL Retail outlets
Inspection and approval of CE marking and Pi marking of Pressure Equipment.
Interface with clients, manufacturers, internal engineers and management.
Select Accomplishments:
• Achieved budget income specified by the management.
• Enhanced business 2-fold in 2 years.
• Excellent interface with customers and management.
• Satisfactory execution of surveillance audits as a State coordinator for IOCL & HPCL
• Satisfactory execution of Surveillance audits of cross country pipelines for GAIL projects.
Inspection of equipment and material viz: Pressure vessels, Heat exchangers, columns, Propane storage bullets, Agitators, Silos, Tanks & piping as per ASME section VIII DIV- 1 & II, drawings, codes, standards & Client specifications.
Penstock pipe fabrication as per ASME Section VIII I & II and as per customer requirements for Tata Hydroelectric Power Projects.
Raw material as per various National and International standards.
Horizontal centrifugal pumps, Vertical turbine pumps as per API, AWWA, HIS, ISO and IS standards.
Various types of valves like butterfly valves, Gate valves, Sluice valves etc.
Rubber lined vessels and tanks.
Corrugated sheets as per JIS G 3302 & 3312 for Exports.
Responsible for Review/ Witness and approval of WPS, PQR, WPQ as per ASME Section IX.
Witnessed Non-destructive examinations like UT, RT, MT, PT & ET.
Witnessed destructive tests (check tests).
Participated in external audits to verify implementation and compliance with company standards, specifications and ISO 9001-1994 on Vendors & Manufacturers
Participated in internal audits to verify implementation and compliance with company’s standards, specifications and ISO 9001-1994
A positive & value added Interaction with clients and third parties.
Selected Accomplishments:
• Satisfactory execution of inspection of pressure vessels and columns at L&T- Hazira for ONGC-Phase III expansion Project
• Satisfactory execution of inspection and coordination of penstock pipes of Tata Power projects.
• Total Quality control activities of Butterfly valves, Knife Gate valves, Control valves & Isolators
• Non-destructive testing- MT, PT, RT & VT.
• Monitored the QC activities of shift QC inspectors.
• Inspected various castings, fabrication and rubber lining at the manufacturer's location.
• Interfaced and coordinated with clients and third party inspection agencies.
• Compiled inspection reports & material test certificates and approval from clients and TPI.
• Participated in external audits of vendors and manufacturers as per the company standards.
Selected Accomplishments:
• Executed various export valves orders, which included inspection at various vendor locations and co-ordination with third party inspection agencies.
• Prepared and developed Non-destructive test procedures, which was well appreciated.
• Involved in 3.7 mtrs. Butterfly Valve and 2.5 mtrs. Butterfly valves and various Export critical valves.
• Inspected various piping viz. End shield cooling system, High pressure & Low pressure water system, Fire water and chilled water systems etc. inside nuclear reactors of Kaiga Nuclear Power plant in India.
• Ensured and maintained quality standards of piping as per specifications, drawings and client requirements.
• Familiarity and knowledge of ASME Section II, Section III, Section VIII & Sec IX.
• Involved in Qualification of Welding Procedures and Welders.
• Inspected and tested materials for welding and NDT.
• Monitored Weld Visual inspection, NDT, hydrostatic test and pneumatic test.
• Compilation and preparation of Manufacturing Record Book (MRB)/Test Pack.
Selected Accomplishments:
• Established Welding and NDT Procedures.
• Executed successful completion of End Shield Cooling System including pneumatic leak test inside two nuclear reactors at Kaiga (1 & 2)
• Involved in completion of various piping systems inside Nuclear Reactor in Kaiga-1 & 2
• Execution, Fabrication and Inspection of Dished ends for various pressure vessel manufacturers.
• Ensured visual and dimensions of dished ends as per the client specifications
• Execution and Inspection of structural fabrication for various workshops and factories
• Compiled all fabrication and inspection reports.
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Bachelor’s Degree in “Mechanical Engineering” from Institution of Engineers India in 1991